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Brand : KTM

Model : 505 XC-F

Category : Moto tout-terrain

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USER MANUAL 505 XC-F KTM

OWNER"S MANUAL 2008 _

505 XC-F ART. NO. 3211227en

Congratulations on your decision to buy a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly.

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below. Chassis number (+ 7) Dealer's stamp

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded. The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold.

All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop prudction of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

ISO 9001(12 100 6061)

PNù Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

1s0s00 REG.NO, 12 100 6061

KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

CONTENTS MEANS OF REPRESENTATION IMPORTANT NOTES LOCATION OF SERIAL NUMBERS. Chassis numbei Type label Engine number. Fork part number. Shock absorber part number OPERATING ELEMENTS... Clutch lever Hot start lever . Hand brake lever Short circuit button Electric starter button Fuel tap (450 SX-F, 505 SX-F). Fuel tap (450 XC-F, 505 XC-F) Opening filler cap Closing filler cap

Shift lever. Foot brake pedal Plug-in stand (450 SX-F, 505 SX-F). Side stand (450 XC-F, 505 XC-F) . TIPS AND HINTS ON PUTTING INTO OPERATION Advice on first use. Running in the engin RIDING INSTRUCTIONS ……. Checks before putting into operation Starting … Starting up. Shifting, riding Braking … Stopping, parking Refueling.….. GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. Important maintenance work to be carried out by an

authorized KTM workshop. (as additional order)... 18 Important checks and maintenance work to be carried out by the rider 18

MAINTENANCE WORK ON CHASSIS AND ENGINE Jacking up the motorcycle… Removing the motorcycle from the work stand

Checking the basic chassis setting with the rider's weight

Compression damping of shock absorber.

Adjusting high-speed compression damping of the shock absorber

Adjusting the low-speed compression damping of the shock absorber …

Adjusting rebound damping of the shock absorber Measuring rear wheel sag unloaded Checking static sag of the shock absorber Check the riding sag of the shock absorber. Adjusting spring preload of the shock absorber À Adjusting riding sag À Removing the shock absorber À Installing shock absorber À Checking basic setting of fork. Adjusting compression damping of fork Adjusting rebound damping of fork

Bleeding fork legs... Cleaning dust boots of fork legs Loosening the fork protection. Positioning the fork protectio: Checking play of steering head bearing Adjusting play of steering head bearing À Fork offset Setting the fork offset À Removing the fork legs À. Installing the fork legs À... Removing the fork protector À. Installing the fork protector À ….

Removing the lower triple clamp À . 30 Installing the lower triple clamp À . 30 Greasing the steering head bearing À . 31

Dismounting the front fender Installing the front fender... Dismount the start number plat Fitting the start number plate Handlebar position Adjusting handlebar position À Checking gas Bowden cable route Checking play in gas Bowden cable. Adjusting play in gas Bowden cable À Checking chain dirt Cleaning the chain. Checking the chain tension Checking the chain tension - fitting rear wheel . Checking rear sprocket / engine sprocket for wear Checking chain wear Adjusting chain tension Adjusting chain tension - after checking Adjusting chain tension - fitting rear wheel … Adjusting chain guide À (450 SX-F, 505 SX-F Adjusting chain guide À (450 XC-F, 505 XC-F) Brake fluid reservoir. Brake calipers Checking brake disc: Checking free play of hand brake lever. Adjusting basic position of handbrake lever Checking front brake fluid level. Topping up the front brake fluid À Checking the front brake linings Removing front brake linings À Mounting front brake linings À Changing the fron brake linings À Checking free play of foot brake lever. Adjusting basic position of footbrake lever À Checking rear brake fluid level Topping up brake fluid of front brake À Checking rear brake linings Removing rear brake linings À. Mounting rear brake linings À . Changing rear brake linings À . Removing front wheel À Fitting front wheel À . Removing rear wheel À. Fitting rear wheel À Tire condition checking Checking tire air pressure Checking spoke tension.

CONTENTS Removing the battery À . Installing the battery À Recharging the battery À Removing a fuse. Replacing the fuse. Ignition curve… Ignition curve plug connection Changing ignition curve. Removing the seat ….

Mounting the seat Dismounting the fuel tank Installing the fuel tank À Cooling system... Checking antifreeze and coolant level Checking the coolant level Draining coolant À …. Refilling coolant À …. Removing main silencer Fitting the main silencer Glass fiber yarn filling of main silencer

Removing glass fiber yarn ing f from the main silencer À

Fitting glass fiber yarn n filling à in main silencer À . Changing glass fiber yarn filling of main silencer À Dismounting the air filter box lid Installing the air filter box li Removing the air filter À Installing the air filter À Cleaning air filter À Adjusting basic position of clutch lever Checking fluid level of hydraulic clutch Changing fluid level of hydraulic clutch Carburetor - idle Carburetor - adiusting ide à. Emptying the carburetor float chamber À Checking engine oil level. Changing engine oil and oil filter, cleaning oil screen Draining the engine oil À Cleaning the oil screen À Removing the oil filter À Mounting oil filter À … Filling up with engine oil À Topping up engine oil … TROUBLESHOOTING. CLEANING Cleaning motorcycle . Storage. Storage. TECHNICAL DATA - ENGINE Capacity- engine oil …. Capacity- cooling liquid. TECHNICAL DATA - ENGINE TIGHTENING TORQUES. TECHNICAL DATA - CARBURETOR TECHNICAL DATA - CHASSIS . Capacity - fuel. TECHNICAL DATA - FORK CAPACITY - FORK OIL.

TECHNICAL DATA - SHOCK ABSORBER TECHNICAL DATA - CHASSIS TIGHTENING TORQUES WIRING DIAGRAM SUBSTANCES AUXILIARY SUBSTANCE: INDE;

MEAN F REPRESENTATION Le

The symbols used are explained in the following.

K Indicates an expected reaction (e.g. of a work step or a function)

Indicates an unexpected reaction (e.g. of a work step or a function)

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

The typographical and other formats used are explained in the following.

Identifies a brand in merchandise traffic

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. f you observe these exactly, you will ensure a much longer service life for your motorcycle.

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and alterations to the motorcycle.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss.

Note Danger of damage Danger of damage by the motorcycle running away or falling over.

Always place the motorcycle on a firm and even surface.

Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

— Do not place the motorcycle where there are flammable or explosive substances.

(450 XC-F, 505 XC-F) — Turn the handle @ of the fuel tap to the ON position. (Figure 400201-10 + 9)

(450 SX-F, 505 SX-F) — Turn the handle @ of the fuel tap to the OFF position. (Figure 400200-10 + 9)

Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

In your own interest, read the specified warning notes.

Various warning labels are attached to your motorcycle. Do not remove any warning labels. 1f they are missing, you or others may not recognize dangers and may therefore be injured.

Danger A Danger that leads immediately and certainly to severe and permanent injury or death.

Warning Danger that will probably lead to severe and permanent injury or death.

Note Danger of serious damage to machine or material.

Warning Risk of environmental damage.

— Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

LOCATION OF SERIAL NUMBERS 1

The chassis number @ is stamped on the right side of the steering head tube.

The type label @ is fixed to the front of the steering head.

The engine number @ is stamped on the left side of the engine under the engine sprocket.

The fork part number @ is stamped on the inner side of the fork stub.

The shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring on the engine side.

OPERATING ELEMENTS 8

The clutch lever @ is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

The hot start lever @ is fitted on the left of the handlebar.

If you pull the hot start lever to the handlebar during the start procedure, a hole is opened in the carburetor to allow the engine to draw in extra air. This gives a leaner fuel-air mixture, which is needed for a hot start.

— Hot start lever in basic position

— Hot start lever pulled

The hand brake lever @ is located on the right side of the handlebar and operates the front wheel brake.

The short circuit button @ is fitted on the left side of the handlebar.

When you press the short circuit button &, the ignition circuit is short-circuited, which stops the engine.

— Short circuit button in basic position

— Short circuit button pressed

The electric starter button @ is fitted on the right side of the handlebar. Pressing the electric start button ® operates the electric starter. Possible states

— Starter button in basic position

— Electric starter button pressed

OPERATING ELEMENTS °

With the tap handle @ on the fuel tap, you can open or close the supply of fuel to the carburetor.

— Fuel supply closed (OFF)

— Fuel supply open (ON)

With the tap handle @ on the fuel tap, you can open or close the supply of fuel to the carburetor.

— Fuel supply closed (OFF)

— Fuel supply open (ON)

— Reserve fuel supply open (RES)

— Press release button ©, turn filler cap counterclockwise and lift it free.

OPERATING ELEMENTS 10

— Replace the filler cap and turn clockwise until the release button @ locks in place.

e Info Run the fuel tank breather hose @ without kinks.

The choke @ is fitted on the left side side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

e Info If the engine is warm, the choke function must be deactivated.

Possible states — Choke function activated

— Choke function deactivated

The shift lever @ is mounted on the left side of the engine.

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

OPERATING ELEMENTS nu

The foot brake pedal @ is located in front of the right footrest and operates the rear wheel brake.

Note Danger of damage Danger of damage by the motorcycle running away or falling over.

— Always place the motorcycle on a firm and even surface.

To park the motorcycle, insert the plug-in stand @ in the left side of the wheel spindle.

e Info Remove the plug-in stand before the journey.

Note Danger of damage Danger of damage by the motorcycle running away or falling over.

— Always place the motorcycle on a firm and even surface.

To park the motorcycle, press the side stand @ with your foot to the ground and lean the motorcycle on it.

When you are riding, the side stand @ must be folded up and secured with the rubber band @.

TIPS AND HINTS ON PUTTING INTO OPERATION 12

Danger Danger of accidents Danger from inadequate traffic experience.

— Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs. Warning Risk of injury Risk of injury by missing/inadequate protective clothing.

— Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle.

Warning Danger of crashing Impairment of riding behavior due to different tire tread patterns on front and rear wheels.

— The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the motorcycle.

Warning Danger of accidents Critical riding behavior due to inappropriate riding.

— Adapt your riding speed to the road conditoins and your riding ability.

Danger of accidents Accident risk caused by presence of a passenger.

— Your motorcycle is not designed to carry passengers. Do not ride with a passenger.

Warning Danger of accidents Brake system failure.

— _lfthe foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake.

Warning Danger of accidents Unstable riding behavior.

— Do not exceed the maximum permitted weight and axle loads.

Warning Risk of misappropriation Usage by unauthorized persons.

— Never leave the motorcycle while the engine is running. Secure the motorcycle against use by unauthorized persons.

e Info (l When using your motorcycle, remember that others may feel disturbed by excessive noise.

— Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

— Before your first trip, read the entire operating instructions carefully.

— Get to know the operating elements.

— _adjust the basic position of clutch lever. (* 60)

— _adjust the basic position of handbrake lever. (+ 39)

— Get used to handling the motorcycle on a suitable piece of land before making a longer trip.

Your motorcycle is not licensed for use on public roads. Offroad, you should be accompanied by another person on another machine so that you can help each other.

— Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle. — Do not make any offroad trips that over-stress your ability and experience.

— Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

— Do not make any changes to the motorcycle, and use only KTM approved parts.

TIPS AND HINTS ON PUTTING INTO OPERATION 13

— If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

e Info Motorcycles react sensitively to any changes of weight distribution.

— Do not exceed the overall maximum permitted weight and the axle loads.

Rules Maximum permissible overall weight 335 kg (738.54 Ib.) Maximum permissible front axle load 145 kg (319.67 Ib.) Maximum permissible rear axle load 190 kg (418.87 Ib.)

— Run the engine in.

Running in the engine — During the running-in phase, do not exceed the specified engine speed and engine performance.

Rules Maximum engine speed During the first 3 service hours 7000 rpm Maximum engine performance during the running-in period During the first 3 service hours < 50 % During the next 12 service hours £<75%

— Avoid fully opening the throttle!

RIDING INSTRUCTIONS Checks before putting into operation

e (l Make sure that the motorcycle is in a perfect technical condition before use.

ll In the interests of riding safety, make a habit of making a general check before you ride.

— Check the engine oil level. (+ 63)

— Check the chain tension. (+ 34)

— Check that all operating elements are correctly adjusted and free to move.

Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness or death.

— When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

— Always warm up the engine at low engine speeds.

evaporate after a long time of standing.

If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel

Conditions Motorcycle standing still: z 1 week - Empty the carburetor float chamber. (+ 63)

(450 XC-F, 505 XC-F)

— Turn the handle @ of the fuel tap to the ON position. (Figure 400201-10 + 9)

7 Fuel can flow from the tank to the carburetor. (450 SX-F, 505 SX-F)

— Turn the handle @ of the fuel tap to the ON position. (Figure 400200-10 + 9)

7 Fuel can flow from the tank to the carburetor. — Remove the motorcycle from the stand. — Shift gear to neutral.

— Pull choke out as far as possible. Conditions

— Pull hot start lever.

e Info Don't open the throttle.

RIDING INSTRUCTIONS 15

— Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

Warning Danger of accidents 1f you change down at high engine speed, the rear wheel can block.

— Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.

e Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

First gear is used for starting off or for steep inclines. — When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

If the choke function was activated, deactivate it after the engine has warmed up.

When you reach maximum speed after fully opening the throttle, turn back the throttle to about 3/4 of its range; the speed hardly drops, but the fuel consumption falls considerably.

Always open the throttle only as much as the engine can handle — abrupt throttle opening increases fuel consumption. To shift down, brake if necessary and close the throttle at the same time. Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

Switch off the engine if you expect to be standing for a long time. Rules

Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system. — Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

Warning Danger of accidents 1f you brake too hard, the wheels can lock.

— Adapt your braking to the traffic situation and the road conditions.

Warning PN Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake.

— Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning Danger of accidents Reduced braking due to wet or dirty brakes.

— Clean or dry dirty or wet brakes by riding and braking gently.

On sandy, wet or slippery surfaces, use the rear brake.

Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.

RIDING INSTRUCTIONS 16

û Warning Danger of burns Some motorcycle components get very hot when the machine is driven.

— Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.

Note Danger of damage Danger of damage by the motorcycle running away or falling over.

— Always place the motorcycle on a firm and even surface. Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running.

— Do not place the motorcycle where there are flammable or explosive substances.

— Apply the brakes and shift into neutral. — To switch off the engine from idle speed, press the short circuit button until the engine stops. — Close the fuel tap, and park the motorcycle on firm ground.

Danger Fire hazard Fuel can easily catch fire.

— Never fill up the motorcycle near open flames or burning cigerettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot motorcycle components. Clean up spilt fuel immediately. — Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

" Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. 1f fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. |f fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning Environmental hazard Improper handling of fuel is a danger to the environment.

— Do not allow fuel to get into the ground water, the ground, or the sewage system.

V4 2 — Open the filler cap. (+ 9) — Fillthe fuel tank with fuel up to measurement @. D Rules Measurement of @: [35 mm (1.38 in) Tank capacity 8.2 1 (2.17 US Super unleaded (+ 82) gal) (450 SX-F, 505 SX-F) D 9.21(2.43 US | Super unleaded (+ 82) 7 40021410 gal) (450 XC-F, 505 XC-F)

— Close the filler cap. (# 10)

17 Important maintenance work to be carried out by an authorized KTM workshop. After 3 service Every 10 Every 30 hours / 20 liters | service hours/ | service hours / of fuel 70 liters of fuel | 210 liters of J'after each fuel race Engine Change the engine oil and oil filter, and clean the oil screen. . Q (+ 64) Replace spark plug. Q Check and adjust valve clearance. . Q Check engine mounting screws for tightness. . Q Clean spark plug connectors and check for tightness. . Q Check shift lever screw for tightness. . Q Carburetor | Check carburetor connection boots for cracks and leakage. Q Check vent hoses for damage and routing without sharp bends. . Q Check idle. . . Attach- Check the cooling system for leakage. . Q ments Check the antifreeze and coolant level. (+ 55) . , Check the exhaust system for leakage and looseness. Q Check Bowden cables for damage, smooth operation and routing . Q without sharp bends. Check the fluid level of the hydraulic clutch. (# 60) . . Clean the air filter. (+ 60) . . Check cables for damage and routing without sharp bends. Q Brakes Check the front brake linings. (* 40) . . Check the rear brake linings. (+ 44) . . Check the brake discs. (+ 38) . . Check the front brake brake fluid level. (+ 39) ° ° Check the rear brake fluid level. (* 43) ° ° Check brake lines for damage and leakage. . Q Check the free play of the hand brake lever. (# 39) . . Check the free play of the foot brake lever. (+ 42) . . Check brake system function. . Q Check screws and guide bolts of brake system for tightness. . Q Chassis Check shock absorber and fork for leakage and functioning. . Q Clean dust boots of fork legs. (+ 26) . Bleed fork legs. (* 26) . Check swingarm bearing. Q Check play of steering head bearing. (+ 27) . . Check all screws to see if they are tight. . Q Wheels Check the spoke tension. (+ 50) . .

Check the tire condition. (# 49)

Checking the tire air pressure. (* 49)

Check the chain wear. (# 35)

Check the chain tension. (+ 34)

Clean the chain. (# 33)

Check wheel bearing for play.

Clean and grease adjusting screws of chain adjuster.

GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

Every 10 Every 20 service hours service 170 liters of | hours / 140

fuel / after liters of each race fuel

Every 40 service hours / 270 liters of fuel

annually every 2 years

Carry out a complete fork service.

Carry out a complete shock absorber service.

Grease the steering head bearing. (+ 31)

Clean and adjust carburetor.

Treat electric contacts with contact spray.

Change hydraulic clutch fluid.

Check wear of clutch discs.

Check long clutch springs.

Check clutch slave cylinder for dents.

Check outer clutch hub for dents.

Check cylinder wear and change pistons.

Check camshaft wear. (visual check)

Check wear of valve spring seat.

Check wear of valve guides.

Change valve springs.

Check the timing-chain tensioner function.

Check crankshaft and crankshaft journal for run-out.

Change conrod bearing.

Check piston pin bearing.

Change the crankshaft main bearing.

Check wear of all transmission components including shafts and bearings.

Check long bypass valve spring.

Change glass fiber yarn filling of main silencer. (+ 59)

Replace foot brake cylinder seals.

Check carburetor components.

Important checks and maintenance work to be carried out by the rider.

Conditions: For use on offroad terrain

according to requirements

Check the engine oil level. (# 63)

Check the front brake brake fluid level. (+ 39)

Check and adjust Bowden cables.

Bleed fork legs. (+ 26)

Clean dust boots of fork legs. (* 26)

Clean the chain. (# 33)

Check the chain tension. (+ 34)

Check the chain wear. (+ 35)

GREASING AND SERVICE TABLE Conditions: For use on offroad terrain

according to requirements

Check rear sprocket / engine sprocket for wear. (+ 35)

Clean the air filter. (+ 60)

Check the tire condition. (# 49)

Check the coolant level. (+ 56)

Empty the carburetor float chamber. (+ 63)

Check that all operating elements for smooth operation.

Check all screws, nuts and hose clamps regularly for tightness.

MAINTENANCE WORK ON CHASSIS AND ENGINE 20

Jacking up the motorcycle

Note Danger of damage Danger of damage by the motorcycle running away or falling over.

— Always place the motorcycle on a firm and even surface.

— Jack up the motorcycle underneath the engine. The wheels must no longer touch the ground.

[Work stand (54829055000)

— Secure the motorcycle against falling over.

Removing the motorcycle from the work stand

Note Danger of damage Danger of damage by the motorcycle running away or falling over.

— Always place the motorcycle on a firm and even surface.

— Remove the motorcycle from the work stand. — Remove the work stand.

Checking the basic chassis setting with the rider's weight

e Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of the suspension components must match your body weight. As delivered, KTM offroad motorcycles are adjusted for a standard rider weight (with full protective clothing).

Standard rider weight 75...85 kg (165.34...187.39 Ib.)

If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accordingly. Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

Compression damping of shock absorber

The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).

The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motorcycle.

The low- and high-speed technology works non-specifically.

Adjusting high-speed compression damping of the shock absorber

Danger Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

e Info ll The high-speed setting can be seen during the fast compression of the shock absorber.

— Turn the adjusting screw @ clockwise with a ring wrench until it stops.

e Info Do not loosen nut @!

MAINTENANCE WORK ON CHASSIS AND ENGINE

Turn back counterclockwise the number of turns corresponding to the shock absorber

type. Rules Compression damping, high-speed (450 SX-F, 505 SX-F) Comfort L'turn Standard L'turn Sport 3/4 turn Compression damping, high-speed (450 XC-F, 505 XC-F) Standard L'turn e Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Adjusting the low-speed compression damping of the shock absorber

Danger Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

e Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

— Turn the adjusting screw @ clockwise with a screwdriver until it stops.

e Info Do not loosen nut @!

— Turn back counterclockwise the number of clicks corresponding to the shock

absorber type. Rules Compression damping, low-speed (450 SX-F, 505 SX-F) ‘40020910 Comfort 16 clicks Standard 14 clicks Sport 12 clicks Compression damping, low-speed (450 XC-F, 505 XC-F) Standard 15 clicks e Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Adjusting rebound damping of the shock absorber

Danger Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any maintenance on it yourself.

MAINTENANCE WORK ON CHASSIS AND ENGINE

— Turn the adjusting screw @ clockwise until it stops.

e Info Do not loosen nut @!

— Turn back counterclockwise the number of clicks corresponding to the shock

absorber type. Rules Rebound damping (450 SX-F, 505 SX-F) 400210-10 Comfort 25 clicks Standard 23 clicks Sport 22 clicks Rebound damping (450 XC-F, 505 XC-F) Standard [23 clicks e Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Measuring rear wheel sag unloaded

— Jack up the motorcycle. (* 20)

— Measure the distance — as vertical as possible - between the rear axle and a fixed point, for example, a mark on the side cover. — Make a note of the value as measurement @.

— Remove the motorcycle from the work stand. (# 20)

Checking static sag of the shock absorber

— Measure distance @ of rear wheel unloaded. (+ 22) — Ask someone to help you by holding the motorcycle upright.

— Measure the distance between the rear axle and the fixed point again. — Make a note of the value as measurement @.

e Info The static sag is the difference between measurements @ and @.

— Check the static sag.

Î Static sag 33 mm (1.3 in)

> Ifthe static sag is less or more than the specified value: — Adjust the spring preload of the shock absorber. (+ 23)

MAINTENANCE WORK ON CHASSIS AND ENGINE Check the riding sag of the shock absorber.

Measure distance @ of rear wheel unloaded. (# 22)

With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a

few times until the rear suspension levels out.

The other person now has to measure the distance between the rear axle and a fixed

point. Make a note of the value as measurement @.

e Info The riding sag is the difference between measurements @ and ©.

Check the riding sag.

Riding sag (450 SX-F, 505 SX-F) 107 mm (4.21 in)

> lfthe riding sag differs from the specified measurement: — Adjust the riding sag. (+ 24)

Adjusting spring preload of the shock absorber à

Danger of accidents The shock absorber is under high pressure.

— The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any

maintenance on it yourself.

Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

Remove shock absorber. (+ 24)

After removing the shock absorber, clean it thoroughly.

Turn adjusting ring @ until the spring is no longer under tension.

Combination wrench (50329080000)

Measure the overall spring length when not under tension.

Tighten the spring by turning adjusting ring @ to measurement @. Rules

Spring preload Ï 7 mm (0.28 in) Tighten screw @. Rules Screw, shock absorber M6 5 Nm (3.69 Ibf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE

— Remove shock absorber. (+ 24) — After removing the shock absorber, clean it thoroughly.

— Choose and fit a suitable spring. Rules

Weight of rider: 65...75 kg (143.3...165.34 Ib.)

Weight of rider: 75...85 kg (165.34...187.39 Ib.)

Weight of rider: 85...95 kg (187.39...209.44 Ib.)

72 N/mm (411.13 Ib/in)

e Info ll The spring rate is shown on the outside of the spring.

Removing the shock absorber à

— Jack up the motorcycle. (+ 20)

— Remove screw @ and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position.

— Remove screw @, push splash protector @ to the side, and remove the shock

— Check parts for damage and wear. Replace damaged or worn parts. — Push splash protector @ to the side and position the shock absorber. Mount and

Rules Screw, top shock | M12 80 Nm Loctite® 243TM (+ 84) absorber (59.01 Ibf ft) — Mount and tighten screw ©. Rules Screw, bottom M12 80 Nm Loctite® 243TM (+ 84) shock absorber (59.01 Ibf ft)

The heim joint for the shock absorber at the swing arm is Teflon coated. It

must not be greased with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.

— Remove the motorcycle from the work stand. (# 20)

MAINTENANCE WORK ON CHASSIS AND ENGINE 25

e Info (l For various reasons, no exact riding sag can be determined for the forks.

As with the shock absorber, smaller weight differences can be compensated by the spring preload.

However, if your fork is often overloaded (hard end stop on compression), you must fit harder springs to avoid damage to the fork and frame.

e Info ll The hydraulic compression damping determines the fork suspension behavior.

— Adjusting screws @ clockwise until they stop.

e Info The adjusting screws @ are located at the top end of the fork legs. Make the same adjustment on both fork legs.

— Turn back counterclockwise the number of clicks corresponding to the fork type.

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

e Info The hydraulic rebound damping determines the fork suspension behavior.

— Remove protection covers @. — Turn the adjusting screws @ clockwise until they stop.

e Info The adjusting screws @ are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.

MAINTENANCE WORK ON CHASSIS AND ENGINE 25

— Turn back counterclockwise the number of clicks corresponding to the fork type.

Rules Rebound damping (450 SX-F, 505 SX-F) Comfort 22 clicks Standard 21 clicks Sport 21 clicks Rebound damping (450 XC-F, 505 XC-F) Standard 21 clicks e Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

— Mount protection covers @.

— Jack up the motorcycle. (# 20)

— Remove bleeder screws @ briefly. 7 Any excess pressure escapes from the interior of the fork.

— Mount and tighten bleeder screws. — Remove the motorcycle from the work stand. (# 20)

Cleaning dust boots of fork legs — Jack up the motorcycle. (+ 20)

— _ Loosen the fork protection. (+ 26)

— Push dust boots @ of both fork legs downwards.

ll The dust boots should remove dust and coarse dirt particles from the fork tube. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

û Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

— Clean and oil the dust boots and inner fork tube of both fork legs. Universal oil spray (+ 84)

— Press the dust boots back into their normal position. — Remove excess oil.

Loosening the fork protection à 7 — Remove screws @ and take off clamp. E — Remove screws @ on left fork leg. Push the fork protection downwards.

— Remove the screws on the right fork leg. Push the fork protection downwards.

MAINTENANCE WORK ON CHASSIS AND ENGINE Positioning the fork protection

Position the fork protection on the left fork leg. Mount and tighten screws @.

Remaining screws, chas- sis

Position brake line. Put the

Position the fork protection Rules

clamp on, mount and tighten screws @.

on the right fork leg. Moun

t and tighten screws.

Remaining screws, chas- sis

Checking play of steering head bearing

Warning Danger of accidents

A Unsafe riding behavior due to incorrect steering head bearing play.

The steering head bearing play should be adjusted immediately in an authorized KTM workshop.

be damaged after time.

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can

Jack up the motorcycle. (+

Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

[ No play should be noticeable in the steering head bearing.

If there is noticeable play present: Adjust play of the steering head bearing (* 27)

Move the handlebar to and fro over the entire steering range.

resting locations should be

The handlebar must be able to move easily over the entire steering range. No

> lfclick positions are noti

Remove the motorcycle from the work stand. (+ 20)

Jack up the motorcycle. (+

Loosen screw @. Remove screw @.

Loosen and retighten screw Rules

Adjust play of the steering head bearing (+ 27) Check the steering head bearing and replace if required.

[ Screw, top steering head

10 Nm (7.38 Ibf ft) ]

Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.

Fully tighten screw @. Rules

Screw, top triple clamp

17 Nm (12.54 Ibf ft)

Mount and tighten screw @. Rules

Screw, top steer- | M8

17 Nm (12.54 lbf ft)

Check play of steering head

MAINTENANCE WORK ON CHASSIS AND ENGINE 28

You can see the currently set offset if you remove screw @.

The fork offset @ has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing.

The fork offset can optionally be adjusted.

Marking @ to the front gives greater stability on fast racetracks.

[For offset: [18 mm (0.71 in) ]

Marking @ to the rear (condition at delivery) gives better handling in bends. [For offset: [20 mm (0.79 in) ]

Removing the fork legs à

— Remove front wheel. (* 46)

— Remove screws @ and take off clamp.

— Remove screws @ and take off brake caliper.

— Hang the brake caliper and the brake line loosely to the side.

— Loosen screw @. Remove the fork leg on the left. — Loosen screw @. Remove the fork leg on the right.

MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fork legs à

Check parts for damage and wear. Replace damaged or worn parts. Position the fork legs.

e (l The topmost sunk nut in the fork leg must be flush to the upper edge of the

upper triple clamp. Position the bleeder screw @ to the front.

Fully tighten screw @. Rules

Screw, top triple clamp M8 17 Nm (12.54 Ibf ft)

Fully tighten screw ©. Rules

Screw, bottom triple M8 clamp

Position brake caliper, mount and tighten screws ©.

Rules Screw, front brake | M8 25 Nm Loctite® 243TM (+ 84) caliper (18.44 lbf ft)

Position brake line. Put the clamp on, mount and tighten screws @. Fit front wheel. (+ 47)

Remove the fork legs. (* 28) Remove screws @ on the left fork leg. Remove the fork protector upwards. Remove the screws on the right fork leg. Remove the fork protector upwards.

Check parts for damage and wear. Replace damaged or worn parts.

Position the fork protection on the left fork leg. Mount and tighten screws @. Rules

Remaining screws, chas- | M6 sis

Position the fork protection on the right fork leg. Mount and tighten screws. Rules

Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft)

— Remove screws @ and hang the CDI control unit to the side.

e Info Do not unplug the CDI control unit.

— Remove screw @. Remove screw ©, take off top triple clamp with the handlebar and place it on one side.

e Info Protect the motorcycle and its attachments from damage by covering them. 500099-10 Do not bend the cables and lines.

— Remove o-ring @. Remove protector ring @. — Remove the lower triple clamp with the steering stem. — Remove the upper steering head bearing.

— Clean the bearing and sealing elements, check for damage, and grease. [ Long-life grease (+ 84)

— Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

e Info Check whether the top steering head seal @ is correctly positioned.

— Push up protective ring @ and o-ring @.

— Position the upper triple clamp with the steering.

— Mount and tighten screw @. Rules

Screw, top steering head | M20x1,5 10 Nm (7.38 Ibf ft)

— Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws ©. Rules

— Install front fender. (+ 31) — Fitthe start number plate. (+ 32) — Install the fork legs. (+ 29)

— Mount and tighten screw @.

Rules Screw, top steer- | M8 17 Nm Loctite® 243TM (+ 84) ing stem (12.54 lbf ft)

— Check the cable harness, cable, brake and clutch line for free movement and free laying — Check play of steering head bearing. (+ 27)

— Remove the lower triple clamp. (+ 30) — Install the lower triple clamp. (+ 30)

— Remove screws @. Remove the front fender — Make sure that the distance bushing remains in place.

— Check parts for damage and wear. Replace damaged or worn parts. — Make sure that the distance bushes are mounted in the fender. — Position the front fender. Mount and tighten screws @.

Rules Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft) sis e Info Take care with the contact between the holding lugs and the start number plate.

— Remove screw @ and take off clamp. — Remove screw @. Remove the start number plate.

MAINTENANCE WORK ON CHASSIS AND ENGINE 32

Fitting the start number plate

— Check parts for damage and wear. Replace damaged or worn parts. — Position the start number plate. Mount and tighten screw @. Rules

Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft) sis

e Info Take care with the contact of the holding lug at the fender.

500123-11 Position brake line. Put the clamp on, mount and tighten screw @. Handlebar position t On the upper triple clamp, there are 2 holes at a distance of @ to each other. Ê k [ Drilling distance A: Ï 15 mm (0.59 in) ] g Ü LP The holes on the handlebar support are placed at a distance of @ from the center. Q 9 ne [Drilling distance B: [3.5 mm (0.14 in) ] 6

The handlebar can be mounted in 4 different positions. This enables you to mount the < handlebar in the position most suitable for the rider.

Adjusting handlebar position à

— Remove the four screws @. Remove the handlebar clamp. Remove the handlebar

u He and lay it to one side. à an 2) i Info

Lo Protect the motorcycle and its attachments from damage by covering them. D) Do not bend the cables and lines.

— Remove the two screws @. Remove the handlebar support. S — Place the handlebar support in the required position. Fit and tighten the two screws

à @. 400271-10 Rules Screw, handlebar | M10 40 Nm Loctite® 243TM (+ 84) support (29.5 lbf ft) e Info

Position the left and right handlebar supports evenly.

— Position the handlebar.

e Info Make sure cables and wiring are positioned correctly.

— Position the handiebar clamp. Fit and evenly tighten the four screws @. Rules

[ Screw, handlebar clamp | M8 I 20 Nm (14.75 Ibf ft) ]

Checking gas Bowden cable route

— The two gas Bowden cables must run parallel behind the handlebar down to the frame. They must be routed directly on the frame above the tank bearing to the carburetor.

MAINTENANCE WORK ON CHASSIS AND ENGINE 33

Checking play in gas Bowden cable

— Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the gas Bowden cable. Rules

[ Play in gas Bowden cable I 3...5 mm (0.12...0.2 in)

> Ifthe gas Bowden cable play does not meet specifications: — Adjust the play in the gas Bowden cable. (+ 33)

Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness or death.

— When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.

— Start the engine and let it run idle. Move the handlebar to and fro over the entire steering range.

[ The idle speed must not change.

> Ifthe idle speed changes: — Adjust the play in the gas Bowden cable. (+ 33)

Adjusting play in gas Bowden cable à

— Dismount the fuel tank. (+ 53)

— Move the handlebar to the straight-ahead position.

— Push back bellows @.

— Loosen nut @. Turn adjusting screw © in as far as possible.

— Loosen nut @. Turn adjusting screw @ so that there is play in the gas Bowden cable at the throttle grip. Rules

[ Play in gas Bowden cable 3...5 mm (0.12...0.2 in)

— Press and hold the throttle grip in the closed setting. Turn adjusting screw © out until there is no play in the Bowden cable @.

— Tighten nut @. — Push bellows @ on. Check the throttle grip for smooth operation. — Install the fuel tank. (+ 54)

— Check the chain for coarse dirt accumulation. > Ifthe chain is very dirty: — Clean the chain. (+ 33)

û Warning Danger of accidents Oil or grease on the tires reduces their grip.

— Remove oil and grease with a suitable cleaning material.

À Warning Danger of accidents

Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

MAINTENANCE WORK ON CHASSIS AND ENGINE sa

e Info The service life of the chain depends largely on its maintenance.

— Clean the chain regularly and then treat with chain spray. Chain cleaner (+ 84) Offroad chain spray (+ 84)

Checking the chain tension

" Warning Danger of accidents Danger caused by incorrect chain tension.

— _lfthe chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if

— Jack up the motorcycle. (# 20) — Push the chain at the end of the chain sliding component upwards to measure the chain tension @.

(l The upper chain section @ must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

I Chain tension 8...10 mm (0.31...0.39 in)

> Ifthe chain tension does not meet specifications: — Adjusting chain tension - after checking (+ 36)

— Remove the motorcycle from the work stand. (# 20)

Checking the chain tension - fitting rear wheel

û Warning Danger of accidents Danger caused by incorrect chain tension.

— Make sure that the chain adjusters are fitted correctly on the adjusting screws.

— Push the chain at the end of the chain sliding component upwards to measure the chain tension @.

D he upper chain section @ must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

[ Chain tension 8...10 mm (0.31...0.39 in)

> Ifthe chain tension does not meet specifications: — Adjust the chain tension when fitting rear wheel. (+ 37)

MAINTENANCE WORK ON CHASSIS AND ENGINE 35

(l When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be replaced together.

400227-01] — Check rear sprocket guides to see whether they are firmly seated.

Jack up the motorcycle. (+ 20) Shift to neutral and pull the upper chain length with the specified tension @. Rules

[ Chain tension 10...15 kg (22.05...33.07 Ib.)

Measure the distance ® of 18 chain links in the lower chain section.

e Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

Maximum distance @ at the longest |272 mm (10.71 in) chain section:

> lfthe distance @ is greater than the specified measurement: — Replace the chain.

e Info When you replace the chain, you should also replace rear sprocket and engine sprocket. New chains wear out faster on old, worn sprockets.

123 16 LAC — Remove the motorcycle from the work stand. (+ 20)

Adjusting chain tension

û Warning Danger of accidents Danger caused by incorrect chain tension.

— Jack up the motorcycle. (+ 20)

— Push the chain at the end of the chain sliding component upwards to measure the chain tension @.

The upper chain section @ must be taut.

Chain wear is not always even, so you should repeat this measurement at different chain positions.

MAINTENANCE WORK ON CHASSIS AND ENGINE 36

Adijust the chain tension by turning the adjusting screws @ left and right.

Rules Chain tension 8...10 mm (0.31...0.39 in) Turn the adjusting screws @ left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks @. The rear wheel is then correctly aligned.

Make sure that the chain adjusters © are fitted correctly on the adjusting screws @.

[Nut, rear wheel spindle ]M20x1,5 [80 Nm (59.01 Ibf ft)

(l The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters @ can be turned by 180°.

Remove the motorcycle from the work stand. (* 20)

Loosen nut @. Loosen nuts @.

Adijust the chain tension by turning the adjusting screws © left and right. Rules

Chain tension I 8...10 mm (0.31...0.39 in)

Turn the adjusting screws © left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks @. The rear wheel is then correctly aligned.

Tighten nuts @. Make sure that the chain adjusters @ are fitted correctly on the adjusting screws ©.

Tighten nut @. Rules

[Nut, rear wheel spindle ” ]M20x1,5 [ 80 Nm (59.01 Ibf ft)

(l The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters @ can be turned by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE 31

— Adjust the chain tension by turning the adjusting screws @ left and right. Rules

Chain tension I 8...10 mm (0.31...0.39 in)

Turn the adjusting screws @ left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks @. The rear wheel is then correctly aligned.

— Loosen screw @. Remove screw @. Swing the chain guide downwards. Conditions

Number of teeth: < 44 teeth

— Insert collar sleeve © in hole @. Position the chain guide.

— Mount and tighten screw @. Tighten screw @. Rules

Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft) sis

Number of teeth: = 45 teeth — Insert collar sleeve @ in hole @. Position the chain guide. — Mount and tighten screw @. Tighten screw @. Rules

Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft) sis

MAINTENANCE WORK ON CHASSIS AND ENGINE 38

— Remove screws @ and @. Take off the chain guide. Conditions Number of teeth: < 44 teeth — Insert nut @ in hole @. Position the chain guide. — Mount and tighten screws @ and @.

Remaining screws, chas- | M6 10 Nm (7.38 lbf ft) sis

Conditions Number of teeth: > 45 teeth — Insert nut @ in hole @. Position the chain guide. — Mount and tighten screws @ and @. Rules

Remaining screws, chas- | M6 10 Nm (7.38 lbf ft) sis

Warning Danger of accidents Brake system failure.

— _lfthe brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn.

The brake calipers of this series are "floating", which means that they are not fixed to the brake caliper support. The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc.

Warning Danger of accidents Reduced braking due to worn brake discs.

—_ Worn brake discs should be replaced immediately in an authorized KTM workshop.

— Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement @.

e Info Wear reduces the thickness of the brake disc around the area used by the brake linings.

Wear limit of brake discs front 2.5 mm (0.1 in) rear 3.5 mm (0.14 in)

> Ifthe brake disc thickness is less than the specified value. — _ Replace the brake disc.

MAINTENANCE WORK ON CHASSIS AND ENGINE 3

Checking free play of hand brake lever

û Warning Danger of accidents Brake system failure.

— _lfthere is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

— Push the hand brake lever forwards and check free play. @.

Free play of hand brake lever z23mm(z>0.12in)

. AP > lfthe free travel does not meet specifications:

= — _adjust the basic position of handbrake lever. (# 39)

Adjusting basic position of handbrake lever

— Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw @.

(l Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!

— Check the free play of the hand brake lever. (+ 39)

Checking front brake fluid level

" Warning Danger of accidents Brake system failure.

À Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

— Move the brake fluid reservoir mounted on the handlebar to a horizontal position. — Check the brake fluid level in the viewer @. > lfthe brake fluid is below MIN the mark: — Top up the brake fluid of the front brake. (+ 40)

MAINTENANCE WORK ON CHASSIS AND ENGINE 40

Topping up the front brake fluid à

û Warning Danger of accidents Brake system failure.

û Warning in il ( Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — _lf brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

À Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Les Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

KTM recommends DOT 5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

— Move the brake fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @. — Remove the cover @ with membrane ©.

— Top up brake fluid to level @. Rules Conditions

[Measurement of @: [5 mm (0.2 in) ]

[Brake fluid DOT 5.1 (+ 82) |

— Check parts for damage and wear. Replace damaged or worn parts. — Replace membrane ©, lid @ and screws @. — Clean up overflowed or spilt brake fluid immediately with water.

Checking the front brake linings

ns Warning Danger of accidents Reduced braking due to worn brake linings.

— Worn brake linings should be replaced immediately in an authorized KTM workshop.

MAINTENANCE WORK ON CHASSIS AND ENGINE ai

— Check the brake linings for thickness @. > Lining thickness @: < 1 mm (< 0.04 in) The lining thickness is less than the specified measurement: — Change the front brake linings. (* 42)

Removing front brake linings à

û Warning Danger of accidents Improper brake maintenance and repair.

— Always have your brake system maintained and repaired in an authorized KTM workshop.

— Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

— Remove the locking split pins @, withdraw the bolt @, and take out the brake pads. — Remove screws © and take off brake caliper. — Clean brake caliper and brake caliper support.

Mounting front brake linings À

û Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

" Warning Danger of accidents Reduced braking due to use of non-approved brake linings.

— Brake linings available from accessory suppliers are often not tested and approved for use on KTM motorcycles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The motorcycle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

— Check the brake discs. (* 38) — Check parts for damage and wear. Replace damaged or worn parts.

— Check that the leaf spring @ in the brake caliper and sliding plate @ in the brake caliper support are seated correctly.

e Info The arrow on the leaf spring points in the rotation direction of the brake disc.

— Fit brake pads, insert bolt ©, and fit locking split pins @. — Position brake caliper, mount and tighten screws @.

Rules Screw, front brake | M8 25 Nm Loctite® 243TM (+ 84) caliper (18.44 lbf ft)

— Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

MAINTENANCE WORK ON CHASSIS AND ENGINE 42

Changing the fron brake linings à

Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — _lf brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

À Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info KTM recommends DOT 5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

— Remove the front brake linings. (# 41)

— Move the brake fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @.

— Remove the cover @ with membrane ©.

— Press the brake piston back to its basic position and make sure that no brake fluid overflows from the reservoir.

— Mount the front brake linings. (+ 41)

— Top up brake fluid to level @. Rules Conditions

[ Measurement of @: 5 mm (0.2 in) ]

I Brake fluid DOT 5.1 (+ 82) |

— Check parts for damage and wear. Replace damaged or worn parts. — Replace membrane ©, lid @ and screws @. Clean up overflowed or spilt brake fluid immediately with water.

Checking free play of foot brake lever

" Warning Danger of accidents Brake system failure.

— If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

— Disconnect spring @.

— Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play @. Rules

Î Free play at foot brake lever 3...5 mm (0.12...0.2 in)

> Ifthe free play does not meet specifications: — Adjust the basic position of the footbrake lever. (+ 43)

— Reconnect spring @.

Adjusting basic position of footbrake lever à

û Warning Danger of accidents Brake system failure.

— _lf there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

Checking rear brake fluid level

Disconnect spring @. Loosen nut @ and with push rod ©, turn it back until you have maximum free play.

To adjust the basic position of the footbrake lever individually, lossen nut @ and turn screw © accordingly.

e Info The range of adjustment is limited.

Turn push rod © accordingly until you have free play @. If necessary, adjust the basic position of the footbrake lever.

I Free play at foot brake lever 3...5 mm (0.12...0.2 in) ] Hold screw @ and tighten nut @.

Î Remaining nuts, chassis Ï M8 Ï 30 Nm (22.13 Ibf ft) ] Hold push rod © and tighten nut @.

I Remaining nuts, chassis [ M6 [ 15 Nm (11.06 Ibf ft) ]

" Warning Danger of accidents Brake system failure.

À Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Stand the vehicle upright. Check the brake fluid level in the viewer @. > When in the viewer @ an air bubble is visible : — Top up the brake fluid of the rear brake. (+ 44)

MAINTENANCE WORK ON CHASSIS AND ENGINE 44

A Warning Danger of accidents Brake system failure.

Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — _lf brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

KTM recommends DOT 5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Use only clean brake fluid from a sealed container!

— Stand the vehicle upright.

— Remove screw @ with membrane @.

— Top up the brake fluid to level @. Brake fluid DOT 5.1 (+ 82)

— Check parts for damage and wear. Replace damaged or worn parts. — _ Refit screw @ with membrane @. — Clean up overflowed or spilt brake fluid immediately with water.

PIN Warning Danger of accidents Reduced braking due to worn brake linings.

— Worn brake linings should be replaced immediately in an authorized KTM workshop.

— Check the brake linings for thickness @. > Lining thickness @: < 1 mm (< 0.04 in) The lining thickness is less than the specified measurement: — Change the rear brake linings. (+ 46)

MAINTENANCE WORK ON CHASSIS AND ENGINE 45

Removing rear brake linings à

û Warning Danger of accidents Improper brake maintenance and repair.

— Always have your brake system maintained and repaired in an authorized KTM workshop.

Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

— Remove the locking split pins @, withdraw the bolt @, and take out the brake pads. — Clean brake caliper and brake caliper support.

Mounting rear brake linings À

û Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

û Warning Danger of accidents Reduced braking due to use of non-approved brake linings.

— Check the brake discs. (# 38) — Check parts for damage and wear. Replace damaged or worn parts.

— Check that the leaf spring @ in the brake caliper and sliding plate @ in the brake caliper support are seated correctly.

e Info The arrow on the leaf spring points in the rotation direction of the brake disc.

— Fit brake pads, insert bolt ©, and fit locking split pins @.

Make sure that the decoupling plate @ is mounted on the piston side of the brake pad.

— Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot.

MAINTENANCE WORK ON CHASSIS AND ENGINE 46

Warning Skin irritations Brake fluid can cause skin irritation on contact.

— Avoid contact with skin and eyes, and keep out of the reach of children. — _lf brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

à Warning Danger of accidents Reduced braking due to old brake fluid.

— Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info KTM recommends DOT 5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands.

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

— Remove the rear brake linings. (* 45) — Stand the vehicle upright. — Remove screw @ with membrane @.

— Press the brake piston back to its basic position and make sure that no brake fluid overflows from the reservoir.

— Mount the rear brake linings. (+ 45) — Top up the brake fluid to level @. Brake fluid DOT 5.1 (+ 82)

— Check parts for damage and wear. Replace damaged or worn parts. — Mount screw @ with membrane @. — Clean up overflowed or spilt brake fluid immediately with water.

Jack up the motorcycle. (+ 20)

Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

Fitting front wheel à

Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.

e Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged.

Remove distance bushing @.

û Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Check parts for damage and wear. Replace damaged or worn parts. Clean and grease shaft seal rings @ and bearing surface @ of the distance bushings. [ Long-life grease (+ 84)

Fit the distance bushings.

Lift the front wheel into the fork, position it, and insert the wheel spindle. Mount and tighten screw @. Rules

Screw, front wheel spin- | M24x1,5 40 Nm (29.5 Ibf ft) dle

Operate the hand brake lever several times until the brake pads are lying correctly on the brake disc.

Remove the motorcycle from the work stand. (# 20)

Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

Fully tighten screw ©. Rules

Screw, fork stub M8 [15 Nm GL.06 Ibf ft) ]

MAINTENANCE WORK ON CHASSIS AND ENGINE 48

Jack up the motorcycle. (+ 20)

Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

Remove chain adjuster @. Withdraw the wheel spindle @ only enough to allow the rear wheel to be pushed forward.

Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.

Holding the rear wheel, withdraw the wheel spindie. Take the rear wheel out of the swing arm.

e Info Do not operate the foot brake when the rear wheel is removed. Always lay the wheel down in such a way that the brake disc is not damaged.

Remove distance bushing @.

à Warning Danger of accidents Reduced braking due to oil or grease on the brake discs.

— Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Check parts for damage and wear. Replace damaged or worn parts. Clean and grease shaft seal rings @ and bearing surface @ of the distance bushings.

Î Long-life grease (+ 84)

Fit the distance bushings.

Lift the rear wheel into the swing arm, position it, and insert the wheel spindle @. Put the chain on.

MAINTENANCE WORK ON CHASSIS AND ENGINE 49

— Position the chain adjuster @. Fit nut ©, but do not tighten it yet. — Check chain tension when fitting rear wheel. (+ 34) — Make sure that the chain adjusters © are fitted correctly on the adjusting screws ©.

[Nut, rear wheel spindle — ]M20x1,5 [ 80 Nm (59.01 Ibf ft)

(l The wide adjustment range of the chain adjusters (32 mm) enables different secondary transmissions with the same chain length. The chain adjusters © can be turned by 180°.

e Info D Eitoniytires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle. The front and rear wheels must be fitted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces.

— Examine the tires for cuts, foreign bodies and other damage. — Check the depth of the tread. > Depth of tread: < 2 mm (< 0.08 in) The tread depth is less than the specified measurement: — Replace the tire(s).

e Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

— Check tire air pressure when tires are cold.

Tire air pressure off road front 1 bar (14.5 psi) rear 1 bar (14.5 psi)

> Ifthe tire pressure does not meet specifications: — Correct tire pressure.

MAINTENANCE WORK ON CHASSIS AND ENGINE 50

Checking spoke tension

A Warning Danger of accidents Unstable riding behavior due to loose spokes.

— If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time. If the spokes are too tight, they can break due to local overload.

Check the spoke tension regularly, especially on a new motorcycle.

— To check spoke tension, tap each spoke with a screwdriver. Rules

Î You should hear a high note.

Spoke nipple, front wheel | M4,5 5 Nm (3.69 Ibf ft) Spoke nipple, rear wheel | M5 5 Nm (3.69 Ibf ft) e Info

If you hear different tone frequencies from different spokes, this is an indication of different spoke tensions.

Removing the battery à

A Warning Risk of injury Battery acid and battery gases cause serious cauterization.

— Keep batteries out of the reach of children.

— Wear suitable protective clothing and goggles.

— Avoid contact with battery acid and battery gases.

— Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

— In the event of skin contact, rinse with large amounts of water. 1f battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a doctor.

— Switch off all power-consuming components and switch off the engine. — Remove the seat (+ 53)

— Disconnect the negative (minus) cable @ of the battery.

— Pull back the plus pole cover @ and disconnect the positive (plus) cable of the battery.

— Hang the rubber band © out to the bottom. — _Liftthe battery up.

— Check parts for damage and wear. Replace damaged or worn parts.

MAINTENANCE WORK ON CHASSIS AND ENGINE si

Place the battery in the battery holder. 450 XC-F, 505 XC-F

Risk of injury Battery acid and battery gases cause serious cauterization.

— Keep batteries out of the reach of children.

— Wear suitable protective clothing and goggles.

— Avoid contact with battery acid and battery gases.

— Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.

— In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a doctor.

Environmental hazard Components and battery acid are a danger to the environment.

— Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Even if there is no load on the battery, it loses power every day.

The charge state and the type of charge are very important for the service life of the battery.

Fast recharging with a high charge current shortens the battery's service life.

If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced. If the battery is discharged from starting, it must be recharged immediately.

If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed. The battery is maintenance-free, i.e., the acid level does not have to be checked.

Switch off all power-consuming components and switch off the engine. Remove the seat (# 53)

Disconnect the minus (negative) cable of the battery to avoid damage to the motorcycle's electronics.

Connect the battery charger to the battery. Switch on the battery charger. Î Battery charger (58429074000)

You can also use the battery charger to test rest potential and start potential of the battery, and to test the generator. With this device, you cannot overcharge the battery.

e Info Never remove the lid @. Charge the battery according to the instructions @ on the battery casing.

MAINTENANCE WORK ON CHASSIS AND ENGINE Removing a fuse

Switch off the charger after charging. Disconnect the battery.

The charge current, charge voltage and charge time must not be exceeded.

Charge the battery regularly when the motorcycle is not in use.:

Mount the seat (+ 53)

Switch off all power-consuming components and switch off the engine.

Dismount the air filter box lid (# 59) Remove the protection cover @.

The fuse @ is located in the starter relay @ under the filter box cover.

A Fire hazard The electrical system can be overloaded by the use of incorrect fuses.

— Use only fuses with the prescribed amperage. Never by-pass or repair fuses.

Possible states — Performance - higher performance

— Soft - better handling

lgnition curve plug connection Possible states

Check parts for damage and wear. Replace damaged or worn parts.

A reserve fuse @ is located in the starter relay. Replace a burned-out fuse @ only by an equivalent fuse.

If the new fuse burns out, contact an authorized KTM workshop.

Replace the protection cover. Install the air filter box lid (+ 59)

Plug connection closed

MAINTENANCE WORK ON CHASSIS AND ENGINE

— Plug connection open

Changing ignition curve — Dismount the fuel tank. (+ 53)

Changing the ignition curve from Performance to Soft. — Open plug connection @. (Figure 400211-10 + 52) 7 Soft - better handling (+ 52)

Change the ignition curve from Performance to Soft.

— Close plug connection @. (Figure 400278-10 + 52) 7 Performance - higher performance (+ 52)

rear and simultaneously push forwards.

— Make sure that the seat is correctly locked in.

— Remove screw @. Lift up the seat at the rear, pull it back and then remove from

— Check parts for damage and wear. Replace damaged or worn parts. — Hook in the seat at the front at the flange adaptor from the fuel tank, lower to the

— Mount and tighten the screw of the seat fixing. Rules ft d

Remaining screws, chas- | M6

Dismounting the fuel tank À

— Remove the seat (+ 53)

MAINTENANCE WORK ON CHASSIS AND ENGINE sa

Danger Fire hazard Fuel can easily catch fire.

— Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

" Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. 1f fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. lf fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

— Close the fuel tap and remove the fuel hose. — Remove screws @ with collar sleeve.

— Remove screw @ with collar sleeve.

— Remove the tube from the fuel tank vent line .

— Pull both spoilers to the side of the radiator bracket © and take the fuel tank away upwards.

Danger Fire hazard Fuel can easily catch fire.

— Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

" Warning Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. 1f fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. lf fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

— Check parts for damage and wear. Replace damaged or worn parts. — Position the fuel tank and fit the two spoilers to the side of the radiator fixing. — Make sure that no cables or Bowden cables are trapped or damaged.

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

— Mount the fuel tank vent hose.

— Fit and tighten screw @ with collar sleeve. Rules

Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft) sis

— Fit and tighten screw @ with collar sleeve. Rules

Remaining screws, chas- | M6 10 Nm (7.38 Ibf ft) sis

— Connect fuel hose. — Mount the seat (+ 53)

The water pump @ in the engine forces the coolant to flow.

The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap @. The specified coolant temperature is therefore permissible without danger of function problems.

Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

Checking antifreeze and coolant level

Warning À Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

— Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

" Warning Danger of poisoning Coolants are poisonous and a health hazard.

— Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

— Stand the vehicle upright.

— Remove the radiator cap.

— Check antifreeze of coolant. -25...-45 °C (-13...-49 °F)

> Ifthe antifreeze of the cooling liquid does not meet specifications: — Correct antifreeze of coolant.

— Check the coolant level in the radiator. I Coolant level @ above radiator fins.: 10 mm (0.39 in) ]

> If the level of the cooling liquid does not meet specifications: — Correct the coolant level. Alternative 1

— _Refit the radiator cap.

Checking the coolant level

A A Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

Warning Danger of poisoning Coolants are poisonous and a health hazard. — Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

— Stand the vehicle upright. — Remove the radiator cap. — Check the coolant level in the radiator. [ Coolant level @ above radiator fins: [ 10 mm (0.39 in) ]

> If the level of the cooling liquid does not meet specifications: — Correct the coolant level. Alternative 1

Alternative 2 [ Coolant (mixed ready to use) (+ 82) ]

— _Refit the radiator cap.

A A Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure.

Warning Danger of poisoning Coolants are poisonous and a health hazard. — Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

— Stand the vehicle upright.

— Place a suitable container under the water pump cover. — Remove screw @. Remove the radiator cap @.

— Completely drain the coolant.

— Fit screw @ with a new seal and tighten it. Rules

[ Screw, water pump cover | M6 I 10 Nm (7.38 Ibf ft) ]

MAINTENANCE WORK ON CHASSIS AND ENGINE 57

Warning Danger of poisoning Coolants are poisonous and a health hazard.

— Avoid contact between coolants and skin, eyes and clothing. lf fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. 1f coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

— Make sure that the screw @ is tightened. — Stand the vehicle upright.

— Pour coolant in up to measurement @ above the radiator fins. Rules

Coolant 1.21(1.27 qt.) Coolant (+ 82) Coolant (mixed ready to use) (+ 82)

400244-10] — Refit the radiator cap. — Make a short test ride. — Check the coolant level. (+ 56)

Warning Danger of burns The exhaust system gets very hot when the motocycle is driven.

— Allow the exhaust system to cool down. Do not touch hot components.

— Disconnect spring @. — Remove screws @ and take off main silencer.

— Check parts for damage and wear. Replace damaged or worn parts.

— Mount the main silencer. Mount and tighten screws @. Rules

Remaining screws, chas- | M6 10 Nm (7.38 lbf ft) sis

— Reconnect spring @.

The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Removing glass fiber yarn filling from the main silencer À

û Warning Danger of burns The exhaust system gets very hot when the motocycle is driven.

— Allow the exhaust system to cool down. Do not touch hot components.

— Remove the main silencer. (+ 57)

Fitting glass fiber yarn filling in main

— Remove screws of end cap @. Remove end cap and external tube @.

— Withdraw glass fiber yarn filling @ from inner pipe @. — Clean the parts you want to use again.

silencer à — Check parts for damage and wear. Replace damaged or worn parts. — Push the glass fiber yarn filling over the inner pipe. — Push the outer pipe over the glass fiber yarn filling. — Insert the end cap in the outer tube. Fit and tighten all screws. — Fitthe main silencer. (+ 57)

MAINTENANCE WORK ON CHASSIS AND ENGINE

— Pull off the air filter box lid in area @ to the side and remove to the front.

Removing the air filter à

— Insert the air filter box lid into the rear area @ and clip it into the front area @.

Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

— Never ride the motorcycle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

— Dismount the air filter box lid (+ 59)

air filter with the air filter support. — Remove the air filter from the air filter support.

— Hang the air filter holder @ out to the bottom and swing it to the side. Remove the

MAINTENANCE WORK ON CHASSIS AND ENGINE 60

Installing the air filter À

— Check parts for damage and wear. Replace damaged or worn parts. — Mount the clean air filter onto the air filter support. — Put in both parts together, position them and fix them with the air filter support @.

e Info (l If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

2 / { — Install the air filter box lid (+ 59) 4 500107-10

Cleaning air filter à

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

e Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

— Remove the air filter. (+ 59) — Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

[ Cleaning substance for foam air filter (+ 84)

e Info Only press the air filter to dry it, never wring it out.

— Oil the dry air filter with a high/quality filter oil. [Oil for foam air filter (+ 84)

— Clean the air filter box. — Check carburetor connection boot for damage and tightness. — Install the air filter (+ 60)

Adjusting basic position of clutch lever

— Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw @.

(l Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.

: 40019511 Do not make any adjustments while riding!

Checking fluid level of hydraulic clutch

e Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid.

MAINTENANCE WORK ON CHASSIS AND ENGINE si

— Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @. — Remove the cover @ with membrane ©. — Check the fluid level. Î Fluid level under top level of container.: | 4 mm (0.16 in) ]

> The fluid level does not comply with specifications. — Correct the fluid level of the hydraulic clutch.

I Hydraulic fluid (+ 82) |

Changing fluid level of hydraulic clutch à

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

— Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. — Remove screws @. — Remove the cover @ with membrane ©.

— Fillthe bleeding syringe @ with the appropriate hydraulic fluid. Bleed syringe (50329050000) Hydraulic fluid (# 82)

— _Inject the liquid into the system until it escapes from the bore hole @ of the master cylinder without bubbles.

— To prevent overflow, drain fluid occasionally from the master cylinder reservoir. — Remove the bleeding syringe. Mount and tighten screws bleeder screw.

— Correct the fluid level of the hydraulic clutch. Rules

Fluid level under top level of container.: I 4 mm (0.16 in)

— Check parts for damage and wear. Replace damaged or worn parts. Replace membrane, lid and screws.

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

e Info The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with the adjustmenr screw @. The idle mixture is adjusted with the idle mixture adjustmenr screw @.

MAINTENANCE WORK ON CHASSIS AND ENGINE 62

Carburetor - adjusting idle à

— Screw in the idle adjusting screw @ until it stops and then to the prescribed basic setting. Rules

Idle mixture adjusting screw Open 1.5 turns

[ Adjustment tool for mixture control screw (77329034000) ]

— Run the engine until warm.

Rules [ Warm-up time: I >5 min ] — Adjust the idle speed with the adjusting screw @. Rules Choke function deactivated (# 10) Idle speed 1600...1650 rpm

— Turn the idle adjusting screw @ slowly until the idle speed begins to fall.

— Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls.

— Adjust to the point between these two positions with the highest idle speed.

(l If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motocyclist will set the mixture about 1/4 of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet. If you can turn the idle adjusting screw to the end without any change of engine speed, you have to fit a smaller idling jet. The idle adjusting screw must not be opened more than two turns. If more than two turns are necessary (rich mixture), use a larger idling jet. After changing the idling jet, start from the beginning with the adjusting steps.

— Adjust the idle speed with the adjusting screw @. Rules

Choke function deactivated (+ 10) Idle speed I 1600...1650 rpm

e Info Following extreme air temperature or altitude changes, adjust the idle speed again.

MAINTENANCE WORK ON CHASSIS AND ENGINE 63 Emptying the carburetor float Ghamber à

Fire hazard Fuel can easily catch fire.

— Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Danger of poisoning Fuel is poisonous and a health hazard.

— Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. 1f fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Warning Environmental hazard Improper handling of fuel is a danger to the environment.

— Do not allow fuel to get into the ground water, the ground, or the sewage system.

Info Carry out this work with a cold engine.

— Turn the handle @ of the fuel tap to the ON position. (Figure 400201-10 + 9) 7 No more fuel flows from the tank to the carburetor.

— Turn the handle @ of the fuel tap to the OFF position. (Figure 400200-10 + 9) 7 No more fuel flows from the tank to the carburetor.

— Guide the hose coming down behind the engine into a suitable container.

e Info Water in the float chamber results in malfunctioning.

— Undo the screw @ (turn it counterclockwise) a few turns and drain the fuel from the float chamber.

— _ Tighten screw @.

e Info The engine oil level can be checked on a cold or hot engine. — Stand the motorcycle upright on a horizontal surface. Conditions

The engine is at operating temperature.

— Check the engine oil level. I The engine oil reaches the top of the viewer @.

>. When the engine oil does not reach the top of the viewer: — Top up the engine oil. (+ 66)

Conditions Engine is cold.

MAINTENANCE WORK ON CHASSIS AND ENGINE FA

— Check the engine oil level.

[ The engine oil reaches the bottom of the viewer @.

> When the engine oil does not reach the bottom of the viewer: — Top up the engine oil. (+ 66)

— Drain the engine oil. (+ 64) — Remove the oil filter. (# 65) — Mount the oil filter. (# 65)

— Fill up with engine oil. (+ 66)

Warning Danger of scalding Engine oil gets very hot when the motocycle is driven.

— Wear suitable protective clothing and gloves. 1f you scald yourself, hold the affected area under cold water immediately.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

e Info Drain the engine oil only when the engine is warm.

— Stand the motorcycle on its side stand on a horizontal surface.

— Place a suitable container under the engine.

— Remove the oil drain plug @.

— Completely drain the engine oil.

— Thoroughly clean the oil drain plug with a magnet.

— Clean the sealing area on the engine.

— Check parts for damage and wear. Replace damaged or worn parts.

— Fitoil drain plug @ with seal ring and tighten it. Rules

Oil drain plug with mag- | M12x1,5 20 Nm (14.75 Ibf ft) net

— Clean the oil screen. (* 64)

Warning Danger of scalding Engine oil gets very hot when the motocycle is driven.

— Wear suitable protective clothing and gloves. 1f you scald yourself, hold the affected area under cold water immediately.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

— Place a suitable container under the engine.

MAINTENANCE WORK ON CHASSIS AND ENGINE 65

— Loosen the plug @ with a few light hammer blows.

— Remove plug @ with oil screen @ and O-rings.

— Completely drain the remaining engine oil.

— Thoroughly clean parts and sealing area.

— Check parts for damage and wear. Replace damaged or worn parts.

— Fit and tighten plug @ with oil screen @ and O-rings. Rules

I Plug, oil screen M32x1,5 30 Nm (22.13 Ibf ft)

Removing the oil filter à

û Warning Danger of scalding Engine oil gets very hot when the motocycle is driven.

— Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

— Place a suitable container under the engine. — Remove screws @. Take off the oil filter cover with the O-ring.

Pull the oil filter insert @ out of the oil filter casing. Circlip pliers reverse (5101201 1000)

— Completely drain the engine oil. — Thoroughly clean parts and sealing area.

— Check parts for damage and wear. Replace damaged or worn parts.

— Lay the motorcycle on its side and fill the oil filter housing to about 1/3 full with engine oil.

— Fillthe oil filter with engine oil and place it in the oil filter container. — Oilthe O-ring of the oil filter cover and mount it with the oil filter cover @.

— Mount and tighten screws. Rules

Screw, oil filter cover M6 10 Nm (7.38 lbf ft)

— Stand the motorcycle up.

MAINTENANCE WORK ON CHASSIS AND ENGINE 66

e Info Too little engine oil or poor-quality engine oil results in premature wear to the engine.

— Remove the screw cap @ on the clutch cover and fill up with engine oil. [ Engine oil I 1.351 (1.43 qt.) I Engine oil (# 82)

— Mount and tighten screw cap @.

Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness or death.

— When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.

— Start the engine and check that it is oil-tight. — Check the engine oil level. (+ 63)

e Info (l Too little engine oil or poor-quality engine oil results in premature wear to the engine.

— Remove the screw cap @ on the clutch cover and fill up with engine oil. Î Engine oil (# 82)

— Mount and tighten screw cap @.

Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness or death.

— Start the engine and check that it is oil-tight.

The engine cannot be cranked (electric starter).

— Recharge the battery. (+ 51) — Check the cause of discharging.

Engine turns but does not start.

— Conduct check (+ 14).

Motorcycle was out of use for a long time and there is old fuel in the float chamber

— Empty the carburetor float chamber. (+ 63)

Fuel feed interrupted

Spark plug oily or wet

— Clean and dry spark plug or replace if necessary.

Electrode distance (plug gap) of spark plug too wide

— Adjust plug gap. Rules spark plug electrode gap 0.7 mm (0.03 in)

Spark plug connector or spark plug defective

Risk of injury The ignition system is under high voltage.

— Do not touch parts of the ignition system. Have work on the ignition system carried out in an authorized KTM workshop.

— Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.

Rules You should see a strong spark on the spark plug.

— If there is no spark, change the spark plug.

— If there is still no spark, remove the spark plug cap from the ignition cable, hold it at the specified distance from the ground contact, and try to start the engine.

— If you now have a spark, replace the spark plug connector.

— If there is no spark, have the ignition system checked.

Short-circuit cable in wiring harness chafed, short-circuit button defective

— Check wiring harness. (visual check) — Check electrical system.

Socket connector of CDI control device, pulse generator or ignition coil oxidized.

— Clean socket connector and treat it with contact spray.

Water in carburetor or jets blocked

Adjusting screws on carburetor distorted

— Have the carburetor adjusted.

Spark plug defective

— Change spark plug.

lgnition system defective

— Have ignition system checked.

Engine does not speed up.

Carburetor running over because float needle dirty or worn.

— Have carburetor checked.

Loose carburetor jets

— Have carburetor checked.

Electronic ignition adjustment defective

— Have ignition system checked.

Engine has too little power.

Fuel feed interrupted

— Check tank vent. — Clean fuel tap. — Clean carburetor.

Air filter very dirty

— Clean the air filter. (+ 60)

Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer.

— Check exhaust system for damage.

— Change glass fiber yarn filling of main silencer. (+ 59)

Valve clearance too little

— Have valve clearance adjusted.

Electronic ignition adjustment defective

— Have ignition system checked.

Engine stalls or is popping into the carburetor.

— Clean and check the fuel system and carburetor.

Engine takes in bad air

— Check rubber sleeves and carburetor for tightness.

Too little coolant in cooling system

— Check the cooling system for leakage. — Check the coolant level. (+ 56)

Too little air stream

— Switch off engine when standing.

Radiator fins very dirty

— Clean radiator fins.

Foam formation in cooling system

High oil consumption

Engine vent hose bent

— Route the vent hose without bends or replace it if necessary.

Engine oil level too high

— Check the engine oil level. (# 63)

Engine oil too thin (low viscosity)

— Change the engine oil and oil filter, and clean the oil screen. (+ 64)

Battery is not charged by generator

Note Material damage Damage and destruction of components by high-pressure cleaning equipment.

— Never clean the motorcycle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning Environmental hazard Problem materials cause environmental damage.

— Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

e Info If you clean the motorcycle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the motorcycle during cleaning.

— Before you clean the motocycle, seal the exhaust system to prevent penetration by water. — First remove coarse dirt particles with a gentle water spray. — Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

[ Motorcycle cleaner (+ 84)

e Info Use warm water containing normal motorcycle cleaner and a soft sponge.

— After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly. — Empty the carburetor float chamber. (+ 63)

û Warning Danger of accidents Reduced braking due to wet or dirty brakes. — Clean or dry dirty or wet brakes by riding and braking gently.

— After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

e Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

— Push back the protection covers on the handlebar instruments to allow water to evaporate.

— After the motorcycle has cooled off, oil or grease all moving parts and bearings.

— Clean the chain. (+ 33)

— Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

[ Cleaning and polishing materials for metal, rubber and plastic (* 84) ]

— Treat all painted parts with a mild paint polish. [ High-luster polish for paint (# 85) ]

— To prevent electrical problems, treat electric contacts and switches with contact spray. [ Contact spray (+ 85) ]

" Warning Danger of poisoning Fuel is poisonous and a health hazard.

according to regulations and keep it out of the reach of children.

If you want to garage the motorcycle for a longer period, take the following actions.

Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the

start of the new season.

Clean the motorcycle. (+ 69) Change the engine oil and oil filter, and clean the oil screen. (+ 64) Check the antifreeze and coolant level. (+ 55)

Remove the spark plug and fill the cylinder with engine oil. Rules

Activate the starter motor to distribute the engine oil over the cylinder wall. Rules

Replace the spark plug.

Drain the fuel from the tank into a suitable container. Empty the carburetor float chamber. (+ 63) Checking the tire air pressure. (# 49)

Remove the battery. (+ 50)

Recharge the battery. (æ 51) Rules

Storage temperature of battery without direct sunshine.: 0.35 °C (32...95 °F)

The storage place should be dry and not subject to large temperature differences.

Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during

combustion condenses and causes valves and exhaust system to rust.

TECHNICAL DATA - ENGINE

1-cyliner 4-stroke engine, water-cooled

4 valves controlled by cam levers ad 2 camshafts, driven by helical gear pair and tooth-wheel chain

Valve clearance, cold, intake

0.07...0.13 mm (0...0.01 in)

Valve clearance, cold, exhaust

0.12...0.18 mm (0...0.01 in)

2 cylinder roller bearing

not a bearing bush - DLC-plated piston pins

1 compression ring, 1 oil scraper ring

Pressure circulation lubrication with 3 rotor pumps

Primary transmission

Transmission ratio (450 SX-F, 505 SX-F)

1st gear 17:32 2nd gear 19:30 3rd gear 21:28 Ath gear 23:26 Transmission ratio (450 XC-F, 505 XC-F) 1st gear 16:34 2nd gear 19:31 3rd gear 20:26 Ath gear 23:25 5th gear 26:24 Generator performance 6000 rpm 42W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK CR 9 EKB

spark plug electrode gap

Water cooling, permanent circulation of coolant by water pump

Screw, clutch cover M6 10 Nm (7.38 Ibf ft) -

Screw, clutch spring M6 10 Nm (7.38 Ibf ft) -

Screw, clutch slave cylinder M6 10 Nm (7.38 Ibf ft) -

Screw, engine housing M6 10 Nm (7.38 Ibf ft) -

Screw, oil filter cover M6 10 Nm (7.38 Ibf ft) -

Screw, oil pump casing M6 10 Nm (7.38 Ibf ft) Loctite® 2437M (+ 84) Screw, shift drum locating M6 10 Nm (7.38 Ibf ft) Loctite® 2437M (æ 84) Screw, shift lever M6 10 Nm (7.38 Ibf ft) Loctite® 2437M (+ 84) Screw, valve cover M6 8 Nm (5.9 lbf ft) -

Screw, water pump cover M6 10 Nm (7.38 lbf ft) _-

Screw, ignition cover M6 10 Nm (7.38 Ibf ft) -

Stud, cylinder head M6 10 Nm (7.38 Ibf ft) -

Screw, clutch cover M7x1 14 Nm (10.33 lbf ft) -

Screw, engine housing M7xl 14 Nm (10.33 Ibf ft) -

Screw, camshaft bearing bridge | M7x1 14 Nm (10.33 Ibf ft) Engine oil (any) (+ 85) Plug, crankshaft location M8 20 Nm (14.75 Ibf ft) -

Screw, unlocking of timing M10x1 10 Nm (7.38 Ibf ft) -

Screw, camshaft gear M10x1 50 Nm (36.88 Ibf ft) Engine oil (any) (+ 85) Screw, ignition rotor M10x1 80 Nm (59.01 Ibf ft) Engine oil (any) (+ 85) Plug, oil channel M10x1 10 Nm (7.38 Ibf ft) -

Plug, cam lever axle M10x1 10 Nm (7.38 Ibf ft) -

Nut, cylinder head M10x1,25 Tightening sequence: Engine oil (any) ( 85)

Tighten in diagonal sequence. Tightening stage 1

10 Nm (7.38 Ibf ft) Tightening stage 2

30 Nm (22.13 Ibf ft) Tightening stage 3

Oil drain plug with magnet M12x1,5 20 Nm (14.75 Ibf ft) -

Axle guide rail for timing chain | M14x1 15 Nm (11.06 Ibf ft) -

Axle tension rail for timing Mi4xl 15 Nm (11.06 Ibf ft) -

Ath position from top

Needle position (505 SX-F, 505 XC-F)

5 th position from top

Idle mixture adjusting screw

Diameter of bore in carburetor body 2.5 mm (0.1 in)

Frame Central tube frame made of chrome molybdenum steel tubing Fork WP 4860 MXMA CC Suspension travel

Front 300 mm (11.81 in)

Rear 335 mm (13.19 in)

WP PDS 5018 DCC Brake system

Disc brakes, brake calipers on floating bearings

Diameter of brake discs

Tire air pressure off road

Rear wheel gearing 14:52

Seat height unloaded

Ground clearance unloaded

Weight without fuel (450 SX-F, 505 SX-F)

104.6 kg (230.6 Ib.)

Weight without fuel (450 XC-F, 505 XC-F)

Maximum permissible overall weight

3Ah battery (450 SX-F, 505 SX-F) YTX4L-BS Battery voltage: 12 V Nominal capacity: 3 Ah maintenance-free AAh battery YTXS5L-BS Battery voltage: 12 V Nominal capacity: 4 Ah maintenance-free Validity Front tire Rear tire (450 SX-F, 505 SX-F) 80/100 - 21 51 M TT Bridgestone M59 110/90 - 19 62 M TT Bridgestone M70 (450 XC-F, 505 XC-F) 80/100 - 21 51 M TT Bridgestone M59 110/100 - 18 64 M TT Bridgestone M402

Tank capacity 8.21(2.17 US gal) (450 SX-F, 505 SX-F) 9.21 (2.43 US gal) (450 XC-F,

Weight of rider: 65...75 kg (143.3...165.34 Ib.)

Weight of rider: 75...85 kg (165.34...187.39 Ib.)

Weight of rider: 85.95 kg (187.39...209.44 Ib.)

5 N/mm (28.55 lb/in)

Spring rate (450 XC-F, 505 XC-F)

Weight of rider: 65...75 kg (143.3...165.34 Ib.)

Weight of rider: 75...85 kg (165.34...187.39 Ib.)

Weight of rider: 85.95 kg (187.39...209.44 Ib.)

WP PDS 5018 DCC Compression damping, low-speed (450 SX-F, 505 SX-F)

Sport 12 clicks Compression damping, low-speed (450 XC-F, 505 XC-F)

Standard 15 clicks Compression damping, high-speed (450 SX-F, 505 SX-F)

Sport 3/4 turn Compression damping, high-speed (450 XC-F, 505 XC-F)

Weight of rider: 65...75 kg (143.3...165.34 Ib.)

Weight of rider: 75...85 kg (165.34...187.39 Ib.)

Weight of rider: 85.95 kg (187.39...209.44 Ib.)

Spoke nipple, rear wheel M5 5 Nm (3.69 Ibf ft) _-

Remaining nuts, chassis M6 15 Nm (11.06 Ibf ft) -

Remaining screws, chassis M6 10 Nm (7.38 Ibf ft) -

Screw, rear brake disc M6 14 Nm (10.33 lbf ft) -

Screw, front brake disc M6 14 Nm (10.33 lbf ft) -

Screw, shock absorber adjust- | M6 5 Nm (3.69 Ibf ft) _-

Screw, ball joint of push rod on | M6 10 Nm (7.38 Ibf ft) -

Nut, rear sprocket screw M8 35 Nm (25.82 Ibf ft) Loctite® 2437M (+ 84) Nut, rim lock M8 10 Nm (7.38 Ibf ft) -

Remaining nuts, chassis M8 30 Nm (22.13 Ibf ft) -

Screw, subframe M8 35 Nm (25.82 lbf ft) Loctite® 2437M (+ 84) Screw, side stand fixing M8 40 Nm (29.5 Ibf ft) Loctite® 2437M (+ 84) Engine carrying screw M10 60 Nm (44.26 Ibf ft) -

Remaining nuts, chassis M10 50 Nm (36.88 lbf ft) -

Remaining screws, chassis M10 45 Nm (33.19 Ibf ft) -

Screw, handlebar support M10 40 Nm (29.5 Ibf ft) Loctite® 2437M (+ 84) Nut, seat fixing M12xl 20 Nm (14.75 Ibf ft) -

11 ignition curve plug connection

— Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

— Motorex® Brake Fluid DOT 5.1

— Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming. KTM recommends Motorex® products.

Antifreeze: -25...-45 °C (-13...-49 °F) 50 % Anti-corrosion/antifreeze

50 % distilled water

— Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

— Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends Motorex® products.

Synthetic engine oil

— Motorex® Cross Power 4T SUBSTANCES 83

— Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.

Specification KTM recommends Motorex® products.

— Motorex® Joker 440 Universal

Specification KTM recommends Motorex® products.

— Motorex® Long Therm 2000

Specification KTM recommends Motorex® products.

— Motorex® Chain Clean 611

Specification KTM recommends Motorex® products.

— Motorex® Chain Lube 622

Specification KTM recommends Motorex® products.

— Motorex® Twin Air Dirt Bio Remover

Specification KTM recommends Motorex® products.

— Motorex® Twin Air Liquid Power

Specification KTM recommends Motorex® products.

— Motorex® Moto Clean 900

Specification KTM recommends Motorex® products.

AUXILIARY SUBSTANCES 85

—_ KTM recommends Motorex® products. Supplier

— Motorex® Moto Polish

—_ KTM recommends Motorex® products. Supplier

Air filter cleaning installing ... removing

Air filter box li dismounting installing ....

Basic chassis setting checking with rider's weight

Battery installing ... recharging .. removing ...

Brake discs checking

Brake fluid level of front brake checking ... Brake fluid of front brake topping Up 40 Brake fluid of rear brake checking ... topping up .. Brake linigs of rear brake mounting removing ... Brake linings of front brake changing ... checking . mounting removing ... Brake linings of rear brake changing ... checking ... Braking

adjusting 37-38 Chain tension

checking 34 Chain wear

cold-start device Compression damping fork, adjusting

Compression damping, high-speed

of shock absorber, adjusting 20 Compression damping, low-speed

of shock absorber, adjusting 21 Coolant

Electric starter button Engine running in

Engine oil changing draining refilling ... toppingup 66

Engine oil level checking

Filler cap closing opening ...

Foot brake pedal Adjusting basic position checking free play

Front fender dismounting installing

Front wheel fitting ... removing ...

Fuse removing replacing

Gas Bowden cable route checking Hand brake lever Adjusting basic position checking free play

Handlebar position .

adjusting .... Hot start lever 8 Ignition curve 52 changing

Lower triple clamp installing removing

changing glass fiber yarn filling . 59 fitting doses 57 fitting glass fiber yarn filling .. 58 removing .. 57 removing glass fiber yarn filling . 58 Motorcycle cleaning 69 Oil filter changing mounting removing ... Oil screen cleaning 64

Play in gas Bowden cable adjusting checking ...

Putting into operation Advice on first use

Rear sprocket / engine sprocket checking for wear

Rear wheel fitting .... removing ..

Rebound damping fork, adjusting of shock absorber, adjusting

Riding sag adjusting

Seat mounting removing ..

Spoke tension checking

Spring preload of shock absorber, adjusting Start number plate dismounting fitting .... Starting Starting up Steering head bearing greasing Steering head bearing play adjusting .. checking .. Stopping, parking Storage . Tire air pressure checking ..

Tire condition checking ..